Cable splice apparatus

ABSTRACT

An improved cable splice joining a pair of cables and a cable splicing tool for forming that splice. The cable splice includes a pair of overlapping cable end portions held together in a common copper sleeve. The sleeve is crimped into compressing contact with the overlapping cable end portions and includes a plurality of crimping indentations formed in a circle around the periphery thereof whereby the cable splice has a tensile strength up to the maximum safe tension of the cables being spliced. A cable splicing tool for crimping the copper sleeve having overlapping cable portions therein comprises a pair of opposed die housings adapted to be fitted together in abutting contact for forming a channel-shaped crimping die for receiving said overlapping cable end portions in a copper sleeve. Each die housing includes a semicircular die extending longitudinally thereof and each die includes pendent means projecting radially inwardly thereof whereby fitting said die housing together in abutting contact may compress said pendent means into said sleeve and overlapping cable end portions for forming a crimped cable splice having desired tensile strength. Thereafter, plastic tape, rubber putty and neoprene filler material may be placed around the splice and held there with a suitable insulating tape for sealing and insulating the spliced cables.

nited States Patent n91 May 1 r v CABLE SPLICE APPARATUS [75] Inventor: Francis A. May, Pittsburgh, Pa.

[73] Assignee: Consolidation Coal Company,

Pittsburgh, Pa.

22 Filed: Sept. 18,1972 211 Appl. No.: 289,603

Related US. Application Data [62] Division of Ser. No. 179,445, Sept. 10, 1971.

Primary Examiner--Thomas H. Eager [57] ABSTRACT An improved cable splice joining a pair of cables and Penfold et al 29/2031) 9 Jan. 8, 1974 a cable splicing tool for forming that splice. The cable splice includes a pair of overlapping cable end portions held together in a common copper sleeve. The sleeve is crimped into compressing contact with the overlapping cable end portions and includes a plurality of crimping indentations formed in a circle around the periphery thereof whereby the cable splice has a tensile strength up to the maximum safe tension of the cables being spliced. A cable splicing tool for crimping the copper sleeve having overlapping cable portions therein comprises a pair of opposed die housings adapted to be fitted together in abutting contact for forming a channel-shaped crimping die for receiving said overlapping cable end portions in a copper sleeve. Each die housing includes a semicircular die extending longitudinally thereof and each die includes pendent means projecting radially inwardly thereof whereby fitting said die housing together in abutting contact may compress said pendent means into said sleeve and I overlapping cable end portions for forming a crimped ,cable splice having desired tensile strength. Thereafter, plastic tape, rubber putty and neoprene filler ma- .terial may be placed around the splice and held there with a suitable insulating tape for sealing and insulating the spliced cables.

2 C a 7 Dra n u e CABLE SPLICE APPARATUS CROSS-REFERENCE TO RELATED APPLICATION This application is a division of United States patent application Ser. No. l79,445, filed Sept. 10, 1971, entitled AN IMPROVED CABLE SPLICE AND APPARATUS THEREFOR.

BACKGROUND OF THE INVENTION and electrical characteristics when compared'with nut and bolt-type couplings. In a compression coupling, the

connector for a pair of wires is usually made from a" ductile metal which may be compressed about the wire conductors by means of specially made tools for exert ing a pressure on the connector andiwires tobe' joined therewith. In some cases, compression tools are pro vided with die grooves or the like. for controlling the shape of the compressed connector. U.S. Pat; No. 2,276,57l discloses asplice for joining together the, bared ends of electrical wires wherein the baredends' of the wires are inserted in a metal tube or sleeve having outwardly flaredend. portions. After inserting. the wire ends in the metal sleeve, the wires are twisted in opposite directions to effect intermingling of the strands of one wire with those of the other. The middle portion of the metalsleeve is then flattenedf by means of pliers whereby the sleeve and wires therein are compressed together to form a splice. That splice willnot permit carefully. controlledstrength ina splice jointbetween a pair of electrical conductors. It isbelieved that in most cases a splice of the type described inthe patent willhave a strength greater than the conductor itself. Hence, further cable failure will result ata location in the cable remote from the splice, thus requiring-additional splices in the same length of cable. Moreover intermingling of the strands of one wire with those of the other can allow stretching of the splice when-the cable splice is under tension. While under tension, pull is placed upon only a part of the intermingled copper strands and' the splice may stretch to thereby destroy an insulating sealon the splice. This is especially. so where the splice wires are under tension much of the time and. required to travel repeatedly over a pulley, for example, as in portable or movable electrical equipment such as that employed in undergroundmining applications where electrically operated'mining machinery advances into a mine while drawing flexible cable, connected to a'powersource, from'a reel. Additionally, the splice there shown comprises a relatively.- long metal sleeve several times the diameter of the cables of the wires being spliced which can result in an unsatisfactory splice for applications where the spliced wires must repeatedly pass over a pulley.

In addition to the pliers described in the above patent for-compressing, or crimping, a wire splice, additional splicing tools have been proposed. For example, hydraulically operated dimpling tools are known. Those tools, though providing a well-crimped splice, permit little or no control'over the splice strength; Overcrimping with such tools iscommon and can weaken the cable splice. to thereby encourage awbreak' at'the splice ends under relatively low-eabletensions. Additionally, splices formed with such toolsvary in strength and are often cocked and bent splices;

Additional compression-type, cable splices are shown in US. Pat. Nos. 2,734,933 and 2,249,492. The former discloses electrical connectors for-joining a tap wire into a through wire while the latter discloses a nut and bolt coupling.

This invention provides animprovedcable splice tool for joining electrical cables, which splice has a controlled, predeterminedtensile strength. Moreover the invention provides an improved compressiontype splice for-wire cableswhich splice has a tensile strength up to, but not in excess of, the maximum safe tension of the cables being-joined. Theinvention further provides a cable splicing tool for forming the improved cable splicein a rapidand efficient-manner. A cable splice according to the invention may be formed in the field, and'is-especially useful inapplications where the splicedcable must pass repeatedly over a pulley. Additionally, the invention provides an improved cable splice of controlledtensile strength which is substantially free from stretching, or other permanent distortion, while inuse. Other advantages of the invention will become apparent as this specification proceeds.

SUMMARY OF THE INVENTION This invention provides an improved cable splice for joining a pair of wire cables, and'a cable splicing tool for forming thatsplice. The cable splice includes a pair of'overlapping wire cable endportions held together in acommon copper sleeve. The sleeve comprises an annular copper sleeve and has flared end=portions for receiving opposed cable end portions in overlapping fashion. The copper sleeve is compressibly crimped into compressing contact with a' pair of overlapping cable end' portions whereby. a plurality of crimping indentationsisformedina circle aroundthe periphery thereof and whereby a cable splice between said pair of cables is formedhaving'atensile strength upto-that of the cables being spliced. Most preferably. the copper sleeve has arelatively. shortlength; more specifically, alength of about twice that of' the diameter of the cables being spliced;

The cable splicing tool for crimping the copper sleeve into compressing contact'witha pair of overlapping cable end'portions thereincomprises a pair of opposed die housings adapted tobe fitted together in abutting contact for forming a channel-shaped crimpingdie. Each die housing includesa-semi-circular die which extends longitudinally thereof. Each semicircular die includes pendent means projecting radially inwardly thereof. Most preferably the pendent means comprise aplurality of ball bearings seated in seats therefor provided in each die housing.

Informing a splice according'to the invention, a pair ofoverlappingcable end portions in a copper sleeve is inserted into one member of the pair of opposed die housings; Thereafter the remaining member is placed atop the sleeve and aforce is exerted on the opposed die housings whereby said housings are urged toward abutting contact and whereby the pendent means are compressed into said sleeve andoverl'apping cable end portions therein for forming a crimped: cable splice havingcrimping indentations located in a circle along the periphery thereof. The die housings are urged toward abutting contact in a manner whereby the cable splice is crimped to a desired degree for providing a cable splice having desired tensile strength. More specifically, the die housings are adapted to bottom out in abutting contact whereby a cable splice is crimped to provide a splice having a tensile strength up to, but not in excess of, the maximum safe tension of the cable being spliced. Most preferably the cable splice has a tensile strength of about 85 percent of that of the maximum safe tension of the cables being spliced.

For providing a cable splice having long life and i being watertight according to the invention, the cable splice as formed hereinabove is first wrapped with a BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a pair of conducting cables, each comprising bundles of individual copper wires;

FIG. 2 shows the wires of FIG. 1 in initial overlapping relationship, one of those wires having a copper sleeve thereon;

FIG. 3 shows the cables of FIG. 2 in overlapping contact within the copper sleeve;

FIG. 4 shows the cables of FIG. 3 spliced according to the invention;

FIG. 4a is a view in section taken along the line AA in FIG. 4;

FIG. 5 shows the spliced cables of FIG. 4 in a preferred watertight seal; and

FIG. 6 shows the splice of the preceeding Figures being formed in a splicing tool according to the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1, a pair of cable end portions 10 is shown wherein a conducting cable 12 has been stripped of its insulation coating 14. Each cable 12 comprises a bundle of individual copper wires 13. In forming a cable splice according to the invention, the ends of cable end portions 12 are trimmed, and one of a pair of such cables is inserted into a malleable metallic sleeve (FIG. 2). Metallic sleeve 20 has flared end portions 22 and comprises an annular copper sleeve having a passageway or opening therethrough. The inner diameter of the sleeve 20 is selected so that there is preferably a clearance area of between 0.040 to 0.050 square inches. It has been found that a clearance area of this size is sufficiently large enough to easily insert the pair of conductors and, as later described, permit crimping or compression of the flared sleeve 20 to properly engage the cable end portions. Also, the inner diameter of the sleeve 20 is preferably selected for different sizes of cable to have this clearance area of between 0.040 and 0.050 square inches to thus provide a common clearance area in the sleeves used for different sized cables. Copper sleeve 20 most preferably has a rather short length. A preferred length for copper sleeve 20 is a length equal to about twice the inside diameter of the sleeve. A longer length for a copper sleeve 20 can result in undesirable bumping of the cable splice as it passes over a pulley. Sleeve 20 is adapted to receive a pair of cable end portions 12 in overlapping relationship. For inserting a pair of cables into sleeve 20, the end of the second cable inserted into the sleeve is preferably flattened somewhat to permit easier entry into the annular passageway of sleeve 20.

In FIG. 2 cable end'portions 12 are shown inserted into sleeve 20 in overlapping fashion. Cable end portions 12 are advanced through sleeve 20 until the ends thereof reach insulating material 14 on the cables. Thereafter, the ends of cables 12 are flattened somewhat about each other to insure effective electrical conduction through the splice. Additionally, the ends of cable 12 are spread over 180 of the opposite conductor shown in FIG. 4a.

A plurality of crimping indentations are formed in sleeve 20. Crimping indentations 30 are formed by means of a cable splicing tool 40 shown in FIG. 6. Cable splicing tool 40 comprises a pair of opposed die housings 42 and 44 adapted to be fitted together in abutting contact. Each of opposed die housings 42 and 44 includes a semi-circular die, 43 and 45, respectively. Dies 43 and extend longitudinally of their respective die housings whereby fitting opposed die housings 42 and 44 together in abutting contact results in formation of a channel-shaped crimping die extending longitudinally through the abutting die housings. Each semicirdular die includes pendent means projecting radially inwardly thereof. In the preferred form of cable splicing tool 40 shown in FIG. 6, those pendent means comprise ball bearings 46. Ball bearings 46 are seated and maintained in position within semi-circular dies 43 and 45 in respective seats 47 formed therein. Each of the seats 47 comprises a hole or bore formed, as by drilling, in die housings 42 and 44. Each of the seats is located along a circle along a vertical section through the channel-shaped die formed of semi-circular dies 43 and 45. Each of. the seats 47 is drilled to a preselected depth within a die housing whereby a desired portion of a ball bearing 46 extends through the wall of a semi-circular die for forming said pendent means projecting radially inwardly thereof. The balls 46 are held in the die housing seats 47 by reason of deep center punch indentations made in the semi-circular dies 43 and 45 at two points near each of the seats 47.

In forming the cable splice according to the invention, a pair of cable end portions 12 in a common copper sleeve 20 is inserted in semi-circular die 45 of die housing 44. Thereafter the housing 42 is placed atop the sleeved cables within the die as shown in FIG. 6 in a manner whereby ball bearing pendent means 46 are located along a circle taken through a vertical section as described hereinabove. To insure proper alignment of the semicircular die cavities, each of the die housing members 42 and 44 is provided with a pair of bores 48 and 49, and 48a and 49a respectively. Those respective bore pairs are adapted to be located in a line for receiving dowel pins 50 and whereby sliding or slipping of opposed die housings 42 and 44 is prevented and whereby ball bearings 46 are properly positioned. The dowel pins 50 are aligned and supported by a substantial base plate 51.

After opposed die housings 42 and 44 have been properly aligned having a pair of cable ends in a copper sleeve located therebetween, a crimping splice may be formed. In forming the splice a force is exerted on the opposed die housings whereby the housings are urged toward abutting contact and whereby ball bearings 46 are compressed into sleeve 20 having overlapping cable end portions 12 therein. In that fashion a crimped cable splice having crimping indentations located in a circle along the periphery thereof is formed. In the preferred cable splicing device in FIG. 6, die housing 42 includes a striking surface 60 extending therefrom. In crimping a cable splice, striking surface 60 may be struck with a suitable tool, such as an ordinary hammer, for exerting force on the opposed die housings and urging them toward each other. Most preferably, in forming a crimped splice, striking surface 60 is first struck a few times to make initial crimping indentations 30 in the cables being spliced within the sleeve 20. Thereafter, the cable is rotated within the die until the initial crimping indentations are substantially in line with the next adjacent ball bearings 46. Striking surface 60 is then again struck with a hammer. Rotation of the cable is continued and likewise is striking of surface 60, until die housing 42 bottoms out on die housing 44, i.e., until the die housings come into abutting contact. It will be appreciated here that by providing a die which bottoms out, the degree of crimping and hence strength of a cable splice, is exactly controlled. ln forming a cable splice according to the invention, it is thus not possible to overcrimp a cable splice. Cable splices according to the invention have a maximum safe tension of up to, but not in excess of, the tensile strength of the cable being spliced. Most preferably the cable splice has a tensile strength of about 85 percent of the maximum safe tension of the cables being spliced. It should also be appreciated here that cable splicing according to the invention can readily be performed in the field, as the only tools required for forming the splice are a cable splicing tool 40 and a hammer or the like. Thus a cable broken during use may be rapidly and efficiently spliced and returned to service.

In FIG. 5, a preferred waterproof, long-life cable splice according to the invention is shown. There a splice between a pair of overlapping cables 12 within a common copper sleeve 20 having crimping indentations 30 therein is provided in the fashion previously described herein. The bare ends of the exposed cable end portions between the flared ends 22 of sleeve 20 and insulation 14 on the cables is wrapped with a strong compressive tape 70. To compress loose ends of cables 12, preferred tapes include fiberglass tape and plastic electricians tape, with fiberglass tape being most preferred. An insulating putty 72 is thereafter spread over the entire splice area between insulating materials 14 on cables 12. Sufficient insulating putty 72 is employed for covering the sleeve and splice area, and for providing a putty fill to a diameter equal to or slightly larger than the outside diameter of insulation 14 on cables 12. A suitable insulating putty is Okonite Filler Putty No. 602758010. A layer of an insulating material 74 may be placed over the puttied spliced area. Preferably that binding material comprises a fiberglass tape.

Thereafter, the surface of insulation 14 on cables 12 is roughened for a length of several inches on either side of the cable splice. A suitable splicing cement is then applied to the entire roughened section and to fiberglass tape 74. The splicing cement preferably comprises a neoprene splicing cement. The entire cementcoated area is thenimmediately covered with a thin covering of an insulating putty 76, of the same material as 72. A final outer layer of insulating tape 78 is applied lengthwise of the splice for additional sealing and insulating purposes. A suitable and preferred insulating tape 78 comprises that commercially available as Okonite No. 35 Red Jacket tape. An end cap 80 for the insulation and sealing materials is provided and may comprise a several layer wrap of an insulating tape, such as the Okonite tape mentioned above. The

I splice as thus prepared is ready for service in an electrisplice having a useful life up to several times that of the expected life for the cables being spliced in application where a flexible cable is repeatedly passed over a pulley or reel.

According to the provisions of the patent statutes, I have explained the principle, preferred construction and mode of operation of my invention and have illustrated and described what I now consider to represent its best embodiments. However, I desire to have it understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.

I claim:

1. A cable splicing tool in forming a splice between a pair of cables in a common metallic sleeve comprising a pair of opposed die housings, each of said die housings having a semicircular die therein, each of said semicircular dies including pendent means projecting radially inwardly thereof, said die housings adapted to be fitted together in abutting contact whereby a channel-shaped crimping die is formed by said die housings, said channel-shaped crimping die extending longitudinally through said housings and adapted to receive said pair of cables in said sleeve, whereby fitting said opposed die housings together in abutting contact provides said pendent means along a circle taken through a vertical section of said channel-shaped die, and whereby said pendent means comes into compression contact with said sleeve for forming crimping indentations therein.

2. The cable splicing tool as set forth in claim 1 wherein said pendent means comprises a plurality of ball bearings, each of said ball bearings seated and maintained in position in said semicircular dies.

3. The cable splicing tool as set forth in claim 2 wherein said plurality of ball bearings is maintained in position in said semicircular dies in seats formed therein, each of said seats comprising a bore in said die housings whereby seating said ball bearings in said seats permits a desired portion of each of said ball bearings to extend beyond the walls of said semicircular dies for forming said .pendent means projecting radially inwardly thereof.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent N Dated January 8,

Inventor) Francis A. May

It is certified that error appears in the above-identified patent and that sa id Letters Patent are hereby corrected as shown below:

In the Abstract Line 1 After 'splice' insert --for-- Inithe Specification Column 3, Line 15 After 'compressive' insert --fiberglass Column 3, Linel'S After tape, first occurrence, delete and insert --and-- Column 3, Line 15 After 'a' delete "rubber" and insert I -filler-- Column 3, After putty delete and insert delete "and finally wrapped again with lines 16 and 17 a compressive tape, most-preferably a fiberglass tape."

Column 3, Line 28 After wires delete and insert showing the cables stripped of their insulation 5 This certificate supersedes Certificate of Correction issued May 14 1974 A Signed and sealed this 5th day of November 1974.

(SEAL) Attest:

McCOY GIBSON JR. A C. MARSHALL DANN Attesting Officer Commissioner of Patents F ORM PO-l 050 (1 0-69) USCOMM-DC 60376-P69 u.s oovzmmzm PRINTING OFFICE 8 69 93 o 35w STATES OFFICE CERTIFICATE CORRECTION Patent No. 3 ,78 3-,4-87 l Dated 1 January 8,-1974,

Inventor) rancis A, May

It is certified that errdr-appear ii the above-identified patent and that said Letters Patent are hereby corrected as shown below:

I'I'n the Abstrdct k M 2 1 A $911655 ing'rt' for- In .phe s ecirication f Cblumn 3" 1315: 153 Aft lcr ina'grt --fiib r ig g.5i Comm: 3, Line IS I Aftbt (first burn6-=de1et I rin lrt -3 5";

: Column 3, 'Lin 15 After a- :djelet and ina a rt colmim 3,, t hlf te rv 5mg: qeljte 5 ind 1;;a;r 1158s '16 and r dlgef 'id finallfy lfinp ed a com zuaive tiapepmost pramm a fibe'rgass t afi'e." v calm 3-, Line; 28 [Afar Gites? deie "1'" m i art V s hbw ihg iiheba'bies stirifiped of theirinulat iong Q 

1. A cable splicing tool in forming a splice between a pair of cables in a common metallic sleeve comprising a pair of opposed die housings, each of said die housings having a semicircular die therein, each of said semicircular dies including pendent means projecting radially inwardly thereof, said die housings adapted to be fitted together in abutting contact whereby a channelshaped crimping die is formed by said die housings, said channelshaped crimping die extending longitudinally through said housings and adapted to receive said pair of cables in said sleeve, whereby fitting said opposed die housings together in abutting contact provides said pendent means along a circle taken through a vertical section of said channel-shaped die, and whereby said pendent means comes into compression contact with said sleeve for forming crimping indentations therein.
 2. The cable splicing tool as set forth in claim 1 wherein said pendent means comprises a plurality of ball bearings, each of said ball bearings seated and maintained in position in said semicircular dies.
 3. The cable splicing tool as set forth in claim 2 wherein said plurality of ball bearings is maintained in position in said semicircular dies in seats formed therein, each of said seats comprising a bore in said die housings whereby seating said ball bearings in said seats permits a desired portion of each of said ball bearings to extend beyond the walls of said semicircular dies for forming said pendent means projecting radially inwardly thereof. 